Footwear with External Safety Toe Cap

ABSTRACT

Footwear includes a sole, an upper secured to the sole for covering a foot of a wearer of the footwear, and an external toe cap located at a toe portion of the upper and outside of the upper to form a portion of an exterior surface of the footwear. The toe cap includes a horizontal bottom flange that extends between the upper and the sole and is secured to the sole with adhesive. The toe cap is also secured to the upper with adhesive

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable

PARTIES TO JOINT RESEARCH AGREEMENT

Not Applicable

REFERENCE TO APPENDIX

Not Applicable

FIELD OF THE INVENTION

The field of the present invention generally relates to footwear and, more particularly, to safety footwear having a rigid toe cap.

BACKGROUND OF THE INVENTION

A safety boot or shoe is a durable boot or shoe that has a protective reinforcement in the toe region which protects the toe region from falling objects or compression. Safety footwear can also have other protective reinforcements such as a midsole plate to protect against punctures from below. The protective reinforcement in the toe region is typically a toe cap concealed within the boot or shoe upper. Toe caps are half-dome-like and formed to the desired toe shape. Although traditionally made of steel, safety toe caps can also be made of composite materials such as Kevlar, carbon fiber, and fiberglass, plastics such as thermoplastic polyurethane (TPU), aluminum, or any other suitable rigid material. Safety boots and shoes are important in the construction industry and in many industrial settings. Occupational safety and health legislation or insurance requirements may require the use of such boots in some settings, and may mandate certification of such boots. In the United States, the applicable standard for protective footwear is ASTM standards F2412-05, Standard Test Methods for Foot Protection and ASTM F2413-05, Standard Specification for Performance Requirements for Foot Protection. OSHA requires compliance of ANSI Z41.1-1991, “American National Standard for Personal Protection-Protective Footwear”.

While safety footwear can be very effective in protecting workers feet, they can often be uncomfortable to wear, especially if you are wearing the wrong size or not breaking them in properly. Even after proper sizing and breaking them in, they may not be as comfortable as desired. Accordingly, there is a need for improved safety footwear that provides increased comfort.

SUMMARY OF THE INVENTION

Disclosed are safety footwear that overcome at least one of the disadvantages of the prior art described above. Disclosed is footwear for covering a foot of a wearer that comprises, in combination, a sole, an upper secured to the sole for covering a foot of a wearer of the footwear, and a toe cap located at a toe portion of the upper and outside of the upper to form a portion of an exterior surface of the footwear. The toe cap partially extends between the upper and the sole and is secured to the sole.

Also disclosed is footwear for covering a foot of a wearer that comprises, in combination, a sole, an upper secured to the sole for covering a foot of a wearer of the footwear, and an external toe cap located at a toe portion of the upper and outside of the upper to form a portion of an exterior surface of the footwear. The toe cap includes a horizontal bottom flange that extends between the upper and the sole and is secured to the sole with adhesive. The toe cap is also secured to the upper with adhesive. The toe cap is located within a recess in the top of the sole.

Also disclosed is a method of making footwear for covering a foot of a wearer. The method comprises the steps of, in combination, securing a toe cap to a sole, and after securing the toe cap to the sole, securing an upper to the sole for covering a foot of a wearer of the footwear. The step of securing the upper to the sole includes extending a toe portion of the upper into the toe cap so that the toe cap is located outside of the upper to form a portion of an exterior surface of the footwear and so that the toe cap partially extends between the upper and the sole.

From the foregoing disclosure and the following more detailed description of various preferred embodiments it will be apparent to those skilled in the art that the present invention provides a significant advance in the technology and art of footwear. Particularly significant in this regard is the potential the invention affords for providing comfortable safety footwear. Additional features and advantages of various preferred embodiments will be better understood in view of the detailed description provided below.

BRIEF DESCRIPTION OF THE DRAWINGS

These and further features of the present invention will be apparent with reference to the following description and drawings, wherein:

FIG. 1 is a perspective view of footwear having an external safety toe cap according to the present invention.

FIG. 2 a fragmented and enlarged cross-section view centrally taken through the footwear of FIG. 1 and showing the toe region.

FIG. 3 is a bottom elevational view of an outsole with the safety toe cap secured thereto of the footwear of FIG. 1.

FIG. 4 is left-side view of the outsole and the safety toe cap of FIG. 3.

FIG. 5 is a top elevation view of the outsole and the safety toe cap of FIG. 3.

FIG. 6 a cross-section view taken along line 5-5 of FIG. 5.

FIG. 7 a cross-section view taken along line 6-6 of FIG. 3.

It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features illustrative of the basic principles of the invention. The specific design features of the footwear as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes of the various components, will be determined in part by the particular intended application and use environment. Certain features of the illustrated embodiments have been enlarged or distorted relative to others to facilitate visualization and clear understanding. In particular, thin features may be thickened, for example, for clarity or illustration. All references to direction and position, unless otherwise indicated, refer to the orientation of the footwear illustrated in the drawings. In general, up or upward generally refers to an upward direction within the plane of the paper in FIG. 1 and down or downward generally refers to a downward direction within the plane of the paper in FIG. 1. Also in general, front or forward generally refers to a direction toward the right within the plane of the paper in FIG. 1 and rear or rearward generally refers to a direction toward the left within the plain of the paper in FIG. 1.

DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS

It will be apparent to those skilled in the art, that is, to those who have knowledge or experience in this area of technology, that many uses and design variations are possible for the footwear disclosed herein. The following detailed discussion of various alternative and preferred embodiments will illustrate the general principles of the invention with regard to a laced work boot. Other embodiments of the present invention suitable for other applications will be apparent to those skilled in the art given the benefit of this disclosure. For example, the present invention is suitable for other types of footwear such as, for example, western-style boots, outdoor boots, duty or military boots, shoes, and the like.

Referring now to the drawings, FIGS. 1 to 7 show a work boot 10 having an external safety toe cap 12 according to the present invention. The illustrated work boot 10 is adapted for use on a right foot but it is noted that a similar but mirror image work boot adapted for the left foot is used in conjunction with the illustrated “right” work boot 10 for form a pair of the work boots. The illustrated work boot 10 includes a sole 14 forming a bottom of the work boot 10 and extending below the boot wearer's foot and an upper 16 extending upward from the sole 14 to cover the boot wearer's foot and a small portion of their lower leg.

The illustrated outsole 14 includes an outsole 18 forming an exterior bottom surface for the sole 14 and an insole 20 located above the outsole 18 and forming an upper interior surface of the sole 14 upon which the boot wearer's foot rests within the upper 16. It is noted that the sole 14 can also include a midsole located between the outsole 18 and the insole 20 and/or a shank 22 forming an arch support within the sole 14. The outsole 18 is the outermost portion of the sole 14 of the boot 10 and forms the bottom surface of which is exposed to wear. The illustrated bottom surface of the outsole 18 is provided with tread. The illustrated outsole 18 is molded of synthetic polymer material but can alternatively comprise any other suitable material such as, for example, rubber, leather or the like. The insole 20 can be attached to the outsole 18, the midsole (if present), and/or the upper 16 or the insole 20 can be removable and/or replaceable. The insole 20 can form the upper most surface on the inside of the bottom of the boot 10 or it can be covered with a sock lining of suitable material. The midsole can be located between the outsole 18 and the insole 20. The midsole can be molded of synthetic polymer material but can alternatively comprise any other suitable material. The midsole is designed to provide the boot 10 with desired characteristics of cushioning, support, and flexibility. The illustrated shank 22 is located at the top of the outsole and below the insole 20 to form an arch support which supports the arch of the boot wearer's food. The shank 22 can comprise steel, fiberglass, wood, and/or plastic. It is noted that the sole 14 can alternatively have any other suitable construction within the scope of the present invention.

The illustrated upper 16 includes a vamp 24 which covers the top and front portion of the boot wearer's foot, a counter or quarter 26 that encloses the heel or rear portion of the boot wearer's foot and is secured to the rear of the vamp 24, and a shaft 28 which fits around the lower leg of the boot wearer's leg and is secured to the top of the vamp 24 and the quarter 26. The shaft 28 has an upper edge which forms an upper opening through which the wearer's foot enters the work boot 10. The illustrated vamp 24 and the shaft 28 cooperate to form an opening 30 at the rearward end of the work boot 10 that is selectively closed by a lace 32 so that the opening 30 can be tightened to secure the work boot 10 to the wearer's foot and loosened to ease entry and exit of the wearer's foot into and out of the work boot 10. The illustrated v shaft 28 is provided with a plurality of eyelets 34 and hooks 36 for the lace 32 as is known in the art. A tongue 38 is also provided at the laced opening as is also known in the art. The illustrated upper 16 also is provided with a lining 40 within its interior. The lining 40 can be secured to the inner surface of the work boot 10 with an adhesive 39 or the like. The lining 40 typically comprises pigskin, glove leathers, heavy twilled cotton or linen fabric, and the like. Additionally, the lining 40 can comprise synthetics such as, for example, Gortex, Sympatex, and the like to provide waterproof and/or sweat dissipating characteristics to the work boot 10. It is noted that the upper 16 can alternatively have any other suitable configuration.

The illustrated components of the upper 16 comprise leather such as, for example, cowhide, pigskin, horsehide, kangaroo skin, and the like but any other suitable material can alternatively be utilized such as, for example exotic leathers or skins, synthetic leather or other synthetic materials, cloth, and the like. The illustrated components of the upper 16 are secured together by stitching but any other suitable means can alternatively be utilized.

The illustrated upper 16 is secured to the sole 14 with a cemented construction where the upper 16 is glued or adhered to the sole 14 with adhesive, or the like. It is noted that the upper 16 can alternatively be secured to the sole 14 using any other suitable construction such as, for example, a welted construction or the like.

The illustrated toe cap 12 is an external toe cap. That is, the toe cap 12 is located outside of the upper 16 and forms a portion of the exterior surface of the work boot 10. The illustrated toe cap 12 is located at a front or toe portion of the upper 16 and is configured to be over the toes of the boot wearer's foot and adapted to permit the natural flexing of the boot wearer's foot during walking.

As best shown in FIGS. 4 to 7, the illustrated toe cap 12 has a body 42 that forms and interior space 44 that is sized and shaped to receive a user's toes therein through a rear opening 46. The illustrated body 42 includes an upper roof 48 which slopes forwardly and laterally in a smooth continuous surface to blend into a front wall 50 and opposite side walls 52, 54 respectively. The body 42 is asymmetrical as is well known in the art. The front wall 50 extends between the opposite side walls 52, 54 on a front side of the body 42 and the rear opening 46 extends between the opposite side walls 52, 54 on the rear side of the body 42. The front wall 50 and the side walls 52, 54 extend generally vertical but may be curved over their entire extent both vertically and horizontally as shown. The front wall 50 and the side walls 52, 54 blend together to form a continuous outer surface. The illustrated body 42 includes an inwardly-turned bottom flange 56 horizontally extending from lower edges of the front and side walls 50, 52, 54 in a continuous manner along the entire lower edge of the body 42. The illustrated bottom flange 56 has a flat lower surface 58 for engagement and attachment to an upper surface 60 of the sole 14 as described in more detail hereinbelow. It is noted that the toe cap 12 can alternatively have any other suitable configuration.

The illustrated toe cap 12 is formed of a material rigid enough to protect toes of the wearer of the work boot 10. The illustrated toe cap 12 comprises a composite material but can alternatively comprise steel, plastic, carbon fiber, fiberglass, aluminum alloy, and the like. The illustrated toe cap 12 is preferably adapted so that, when installed in the footwear, it is in compliance with ASTM standard F2412-05 (“Standard Test Methods for Foot Protection”) and ASTM standard F2413-05 (“Standard Specification for Performance Requirements for Foot Protection”) and/or in compliance with ANSI Z41.1-1991 (“American National Standard for Personal Protection-Protective Footwear”).

The illustrated toe cap 12 and the illustrated outsole 18 are preferably molded as separate components. The illustrated toe cap 12 is directly secured to the top front surface of the outsole 18 with a suitable adhesive 19. It is noted, however, that the toe cap 12 can alternatively be secured to the outsole 18 in any other suitable manner such as, for example, co-molding and the like. The illustrated outsole 18 also a recess 62 sized and shaped for partially and closely receiving the toe cap 12 therein. The illustrated recess 62 forms an abutment 64 sized and shaped to engage the inner edge 66 of the bottom flange 56 of the toe cap 12 to limit relative movement between the toe cap 12 and the outsole 18 in horizontal directions (best seen in FIGS. 6 and 7). It is noted that the abutment 64 can take any other suitable form to interlock the components in the horizontal direction. With the toe cap 12 located with the recess 62, the illustrated outsole 18 partially extends upward along and covers the exterior or outer side surface of the body front wall 50 (best seen in FIG. 6) and also partially extends upward along and covers the exterior or outer side surfaces of the body side walls 52, 54 (best seen in FIG. 7) to further limit relative movement between the toe cap 12 and the outsole 18 in horizontal directions. The toe cap 12 can be secured to the outsole 18 with a suitable adhesive 19 located at the exterior surface of the bottom flange 56 and/or at the exterior or outer side surfaces of the body walls 50, 52, 54.

As best seen in FIG. 2, the front or toe portion of the upper 16 extends into the interior cavity 44 of the toe cap 12 and the toe cap 12 is secured to the upper 16 with adhesive 17. Thus, the illustrated toe cap 12 is secured to both the outsole 18 and the upper 16 with adhesive 17, 19. It is noted that the bottom flange 56 of the toe cap 12 extends below the upper 16 so that the horizontal bottom flange 56 rearwardly extends between the front lower edge of the upper 16 and the outsole 18. The illustrated work boot 10 includes the liner 40 that is located within the work boot 10. The liner 40 is secured to the inner side of the upper 16 and the inner or upper side of the outsole 18. The illustrated insole 20 is located above the outsole 18 and the toe cap bottom flange 56 with the liner 40 extending therebetween. Alternatively, the liner 40 can be eliminated if desired.

The illustrated work boot 10 also includes a strip of anti-scuffing or anti-abrasion material 68 along the edge of the toe cap 12 at the outer surface of the upper 16. The anti-scuffing or anti-abrasion material 68 is intended to reduce scuffing or abrasion of the outer 16 near the toe cap 12, particularly when the outer 16 comprises leather. The illustrated anti-scuffing or anti-abrasion material 68 extends partially between the toe cap 12 and the upper 16 and is secured to both the toe cap 12 and the upper 16 with adhesive 17. The anti-scuffing or anti-abrasion material 68 can alternatively be secured in any other suitable manner. The anti-scuffing or anti-abrasion material 68 can also be eliminated when not desired. The anti-scuffing or anti-abrasion material 68 can comprise any suitable material such as, for example, nylon and the like.

Configured in this manner, the toe cap 12 is located external of the upper 16 and thus is separated from the wearer's toes by the upper 16. This configuration enables the work boot 10 to have increased comfort similar to a non-safety work boot. The toe cap 12 also forms a portion of the outer surface of the work boot 10 and is substantially exposed. That is, uncovered or free of any type of covering. The illustrated outer surface of the toe cap 12 can be provided with decorative indicia that will be seen such as, for example, the shown plurality raised ridges 70. The decorative indicia can alternatively be eliminated if desired.

As noted above, the illustrated toe cap 12 and the illustrated outsole 18 are preferably molded as separate components and then secured together with adhesive 19. Thus, the footwear 10 can be made by first securing the toe cap 12 into the recess 62 at the top front of the sole 14 with adhesive 19. Then, after securing the toe cap 12 to the sole 14, securing the upper 16 to the sole 20 for covering a foot of a wearer of the footwear 10. The step of securing the upper 16 to the sole includes extending a toe portion of the upper 16 into the toe cap 12 so that the toe cap 12 is located outside of the upper 16 to form a portion of an exterior surface of the footwear 10 and so that the toe cap 12 partially extends between the upper 16 and the sole 14. The upper 16 is preferably secured to both the toe cap 12 and the sole 14 with adhesive.

Any of the features or attributes of the above the above described embodiments and variations can be used in combination with any of the other features and attributes of the above described embodiments and variations as desired. It is noted that the footwear 10 can alternatively be made by any other suitable method.

It is apparent from the forgoing disclosure and detailed description that the present invention provides a work boot 10 which has improved comfort over prior work boots having a safety to cap.

From the foregoing disclosure and detailed description of certain preferred embodiments, it is also apparent that various modifications, additions and other alternative embodiments are possible without departing from the true scope and spirit of the present invention. The embodiments discussed were chosen and described to provide the best illustration of the principles of the present invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the present invention as determined by the appended claims when interpreted in accordance with the benefit to which they are fairly, legally, and equitably entitled. 

What is claimed is:
 1. Footwear for covering a foot of a wearer, said footwear comprising, in combination: a sole; an upper secured to the sole for covering a foot of a wearer of the footwear; a toe cap located at a toe portion of the upper and outside of the upper to form a portion of an exterior surface of the footwear; and wherein the toe cap partially extends between the upper and the sole and is secured to the sole.
 2. The footwear according to claim 1, wherein the toe cap extends between a front lower edge of the upper and the sole.
 3. The footwear according to claim 1, wherein a horizontal bottom flange of the toe cap extends between the upper and the sole.
 4. The footwear according to claim 1, wherein the toe cap is secured directly to the sole.
 5. The footwear according to claim 1, wherein the toe cap is secured to the sole with adhesive.
 6. The footwear according to claim 1, wherein the toe cap is secured to the upper with adhesive.
 7. The footwear according to claim 1, wherein the toe cap comprises a composite material.
 8. The footwear according to claim 1, wherein the upper comprises leather.
 9. The footwear according to claim 1, wherein the toe cap is located within a recess in the top of the sole.
 10. Footwear for covering a foot of a wearer, said footwear comprising, in combination: a sole; an upper secured to the sole for covering a foot of a wearer of the footwear; and an external toe cap located at a toe portion of the upper and outside of the upper to form a portion of an exterior surface of the footwear; wherein the toe cap is secured to the upper with adhesive; and wherein the toe cap is located within a recess in the top of the sole.
 11. The footwear according to claim 10, wherein the toe cap includes a horizontal bottom flange that extends between the upper and the sole and is secured to the sole with adhesive.
 12. The footwear according to claim 10, wherein the toe cap is secured directly to the sole.
 13. The footwear according to claim 10, wherein the toe cap comprises a composite material.
 14. The footwear according to claim 10, wherein the upper comprises leather.
 15. A method of making footwear for covering a foot of a wearer, said method comprising the steps of, in combination: securing a toe cap to a sole; after securing the toe cap to the sole, securing an upper to the sole for covering a foot of a wearer of the footwear; and wherein the step of securing the upper to the sole includes extending a toe portion of the upper into the toe cap so that the toe cap is located outside of the upper to form a portion of an exterior surface of the footwear and so that the toe cap partially extends between the upper and the sole.
 16. The method according to claim 15, wherein the toe cap is secured to the sole with adhesive.
 17. The method according to claim 15, further comprising the step of securing the upper to the toe cap with adhesive.
 18. The method according to claim 15, wherein the upper is secured to the sole with adhesive.
 19. The method according to claim 15, wherein a horizontal bottom flange of the toe cap extends between the upper and the sole.
 20. The method according to claim 15, further comprising the step of locating the toe cap within a recess in the top of the sole. 